Automotive side bar

ABSTRACT

A Nerf bar incorporates brackets for attachment to a vehicle; the bar is divided into sections to permit the Nerf bar to be economically packaged for shipment. The Nerf bar sections are secured to each other through the use of a support rail mounted internally of the Nerf bar sections and extending across the joint formed by the abutting contact of the respective sections. The Nerf bar sections are maintained in alignment through the use of a joint sleeve having an alignment pin that engages corresponding notches provided in the ends of each of the abutting sections.

FILED OF THE INVENTION

[0001] The present invention relates to automotive accessory equipment,and specifically, to automotive side bars or Nerf bars.

BACKGROUND OF THE INVENTION

[0002] Modem pick-up trucks, sport utility vehicles, and other vehiclesthat are designed with door sills that are positioned relatively highfrom the ground are sometimes uncomfortably high for persons enteringthe vehicle. Since vehicles generally no longer include running boardsor the like, it is frequently desirable to employ an accessory devicethat provides an intermediate step for a prospective occupant of thevehicle to use when mounting or dismounting the vehicle.

[0003] It has therefore become common for owners of such vehicles toattach an accessory product known in the industry as a side bar or Nerfbar. These Nerf bars are sometimes built sufficiently strong to provideprotection to the door sills of the vehicle when such vehicles are usedfor rugged terrain off-road use. However, the more common usage of suchNerf bars is to provide a step to assist an occupant when entering orleaving the vehicle. Frequently, such Nerf bars are employed primarilyas a decorative additive to be mounted on the vehicle to enhance thelatter's appearance.

[0004] Such side bars or Nerf bars are usually produced to fit aspecific vehicle such that the side bar will extend from some positionforward of the front door of the vehicle to a position aft of the reardoor of the vehicle; similarly sometimes the Nerf bars extend rearwardlyof the vehicle to permit the bar to be used as a step to access the bedof a pick-up truck. The Nerf bars are therefore bulky items and whenshipped to a vehicle owner or purchaser, the shipping charges attendantthe long awkward length of the bar renders the shipping costssubstantial. That is, shippers normally charge in accordance with acombination of weight, length, and width of a product being shipped.When the product is extraordinarily long, as in the case of Nerf bars,the shipping charges may be significantly increased as a result ofpenalties added because of the bar's length.

OBJECTS OF THE INVENTION

[0005] It is therefore an object of the present invention to provide aside bar or Nerf bar that can be economically shipped from a point oforigin to a site of distribution or purchaser.

[0006] It is still another object of the present invention to provide aNerf bar that may conveniently be packaged in a more economical mannerwhile providing convenient assembly by the purchaser.

[0007] It is still another object of the present invention to provide aNerf bar that is divided into sections, each of which may beconveniently oriented with respect to adjacent sections and all of whichmay be conveniently joined to provide a unitary structure.

[0008] These and other objects of the present invention will becomeapparent to those skilled in the art as the description thereofproceeds.

SUMMARY OF THE INVENTION

[0009] The present invention comprises a Nerf bar that is divided intosections to permit the bar to be packaged in a convenient manner foreconomical shipment. When the bar arrives at its point of use, thesections are conveniently assembled through the utilization of a supportrail mounted within the tubular Nerf bar together with fastenersprovided for securing the sections together. An alignment notch isprovided in each section that registers with an alignment pin providedin the interior of a joint sleeve to permit the sections of the bar tobe aligned to insure proper orientation of the sections with respect toeach other and to facilitate mounting of the bar to a vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1A is a perspective view showing the side of a vehicle havinga Nerf bar constructed in accordance with the teachings of the presentinvention attached thereto;

[0011]FIG. 1B is an enlarged exploded view of the Nerf bar of FIG. 1A;

[0012]FIG. 2 is a cross-sectional view of the Nerf bar of FIG. 1A takenalong line 2-2;

[0013]FIG. 3 is a cross-sectional view of the Nerf bar of FIG. 2 takenalong line 3-3;

[0014]FIG. 4 is a side elevational view of a portion of the Nerf bar ofFIG. 1, partly in section, showing the joint between adjacent sectionsof the Nerf bar;

[0015]FIG. 5 is a cross-sectional view of a portion of FIG. 4 takenalong line 5-5; and

[0016]FIG. 6 is a perspective view of the joint sleeve of the Nerf barshown in FIG. 1A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] Referring now to FIG. 1A, a vehicle 10 is shown to which the Nerfbar 12 of the present invention has been mounted. The Nerf bar 12extends from beneath the vehicle 10 (where it has been secured throughthe use of brackets) outwardly from the side of the vehicle and alongthe side of the vehicle parallel to the vehicle side. The Nerf bar maybe formed in any convenient manner, but is typically constructed ofrigid tubular material such as tubular steel that will conventionally bechrome plated. The bar incorporates steps 14 and 15 that are generallypositioned along the side of the vehicle where it is likely that anoccupant will place his foot while entering or leaving the vehicle. Inthe embodiment shown in FIG. 1A, the vehicle is a pick-up truck whereinit may be seen that step 14 is positioned to facilitate either theentrance to or the examination of the bed 16 of the pick-up truck whilestep 15 is positioned adjacent the door 18 of the pick-up to permit aprospective occupant to place his foot on the step 15 and enter thevehicle.

[0018] The steps 14 and 15 are usually formed by providing a flatportion of the tubular Nerf bar and covering the flattened portion witha rigid plastic or rigid rubberized cover that may incorporate a treaddesign to help stabilize the footing of the occupant as he places hisfoot on the step. The flattened portions of the Nerf bar that areadapted to receive the plastic or rubberized steps may be formed in anywell known prior art manner. For example, that portion of the Nerf bartube that is to receive the step may be stamped to collapse the tubingand may be provided with means for receiving mounting screws (not shown)to secure the step covers thereto in a manner well known in the priorart.

[0019] Referring now to FIG. 1B, the Nerf bar of FIG. 1A is shown in anenlarged and exploded view. It may be seen that the tubular Nerf bar isprovided with mounting brackets 20 and 22 at either end thereof forattachment to the vehicle. The mounting brackets will usually compriseflat plates 24 and 26, respectively, welded or otherwise secured to theends of the tubular Nerf bar and be of such shape and dimension toprovide secure contact with the frame, or other supporting structure, ofthe vehicle. Normally these mounting brackets are provided with aplurality of holes 28 to accept bolts for attachment to the vehicleframe. The tubular bar forming the Nerf bar 12 extends from therespective mounting brackets and is bent at a 90° angle to form astraight section 30 running parallel to the side of the vehicle. Therespective steps 14 and 15 are positioned as described above inconnection with FIG. 1A. The overall length of the Nerf bar is thereforedetermined by the respective vehicle with which it is intended to beused and is also determined by the availability of attachment points forthe mounting brackets. As described above in connection with thebackground of the invention, the length of the Nerf bar in comparison toits widest dimension and weight renders the shipment of Nerf barsexpensive. That is, the length of the Nerf bars is such that a penaltyis imposed by shipping organizations. To avoid payment of such shippingcosts, the present invention is shipped in sections. In the embodimentchosen for illustration, the Nerf bar is divided into two sections, afront section 32 and rear section 34. The two sections may each containone or more steps and are positioned and mounted in a conventionalmanner when the sections have been joined. The sections are joined atthe abutting ends 36 and 38 of the sections 32 and 34, respectively, andare aligned through the utilization of alignment notches 40 and 42,respectively, provided in each of the sections at the abutting endsthereof. A joint sleeve 44 is provided that is sized to closely slideover the exterior of the respective sections and cover the joint betweenthe sections. In the embodiment chosen for illustration, the alignmentnotches are semicircular.

[0020] Referring now to FIGS. 2 through 6, the joint 48 between thefront and rear sections 32 and 34 is formed by the ends of therespective sections, each of which includes an alignment notch 40 and42, respectively. In the embodiment chosen for illustration the notchesare semicircular; however, other configurations may be used and pluralnotches may be used. The respective notches of the front and rearsection are maintained in alignment through the utilization of analignment pin 50 that is formed in the interior of the joint sleeve 44.The joint sleeve may be formed of any rigid material; however, rigidplastic material may conveniently be molded to have an internalalignment pin 50 that may be cylindrical in shape so that the diameterof the pin closely conforms to the slightly larger diameter of thesemicircular notches provided in the ends of the respective Nerf barsections. As indicated previously, plural alignment pins may be used andthe specific shape of the pins may vary depending on the shape chosenfor, the alignment notches provided in the ends of the respective Nerfbar sections. The joint sleeve 44 may also be provided with moldedridges 52 as a decorative addition to the sleeve. Such decorative ridgesmay typically be formed in a manner similar to the tread patternsprovided on the respective steps to enhance the overall appearance ofthe assembled Nerf bar. Thus, the joint sleeve 44, when in its mountedposition, covers the joint between the respective Nerf bar sections andpresents a decorative exterior; further, the Nerf bar provides thealignment pin 50 to facilitate the alignment of the adjacent Nerf barsections by contacting the respective notches 40 and 42 provided in thesections.

[0021] The front and rear sections 32 and 34 of the Nerf bar, havingbeen aligned through the utilization of the joint sleeve 44 andspecifically the alignment pin 50 of the joint sleeve nesting within theopposing alignment notches 40 and 42 of the front and rear sections, maynow be secured in this aligned position. When the sections of the Nerfbar have thus been aligned with the respective ends in abutting contactwith each other, the sections are secured to form a unitary structurethrough the utilization of a support rail 60 mounted within the opposingsections of the tubular Nerf bar. The support rail 60 is preferably of a“V” cross-sectional shape that extends across the joint 48 between theNerf bar sections and incorporates legs 62 and 64 that extendapproximately 90° with respect to each other from the apex 66 of thecross-sectional configuration. These legs contact the interior wall 68of the tubular Nerf bar. A convenient means for securing the tubularNerf bar sections and support rail in place may be support railfasteners such as bolts or machine screws 70 extending through holes 72provided in the Nerf bar sections and through holes 74 providedtherefore in the support rail into locking engagement with nuts 76 thatare welded in place to the support rail. As may be clearly seen in FIG.3, when the bolt is tightened, it draws the support rail downwardlycausing intimate and firm contact between the respective edges 78 of thelegs of the V-shaped rail and the interior surfaces of the respectiveNerf bar sections. The tightening of the fasteners or bolts results in aNerf bar joint that is extremely rigid and strong while maintainingalignment between the sections.

[0022] As shown in FIG. 3, the axis 78 of the bolts may be positionedalong an alternate axis 80 having offset angle θ from vertical so thatthe bolt heads are positioned closer to the vehicle when the Nerf bar ismounted to make the bolts less visible to users or viewers of theinstalled Nerf bar. The support rail preferably incorporates a “V”cross-section as shown and described above. However, othercross-sectional configurations for the support rail may be used. Forexample, the cross-sectional configuration could be a “U” shape with thelegs of the “U” spread outwardly to contact the interior walls of thetubular Nerf bar in a manner similar to that shown in the preferredembodiment.

[0023] When the Nerf bar is shipped in its disassembled condition, themaximum length of the resulting package is approximately only one halfthe length of the assembled Nerf bar. Therefore, the shipping package ismore efficiently constructed and penalties for shipping package lengthare no longer encountered. When the disassembled Nerf bar is received,the joint sleeve 44 is positioned on one of the Nerf bar sections bysliding the sleeve over the end of the section until the alignment pin50 engages and nests within the corresponding alignment notch 40 or 42.The second Nerf bar section, with the support rail attached thereto andextending outwardly from the end of the section is then slid into theopen end of the joint sleeve 44 until the alignment notch therein abutsthe alignment pin of the sleeve. In this latter position, the sectionsare aligned with their respective notches engaging the alignment pin ofthe sleeve and with their ends abutting. The bolts or machine screws 70are then tightened to draw the edges of the legs of the V-shaped railinto contact with the interior surfaces of the respective sections. TheNerf bar may then be mounted on the vehicle in conventional manner byattaching the mounting brackets to the appropriate locations on thevehicle. The resulting structure is a unitary Nerf bar structure havinga joint sleeve covering the joint between the respective sections of theNerf bar with the support rail firmly and rigidly connecting the twosections and providing both bending and torsional strength to the Nerfbar at the joint. The fasteners such as the machine screws or bolts 70are out of the direct line of site of the observer since they arepositioned on the bottom of the Nerf bar aimed slightly toward thevehicle in a hidden position. The installed Nerf bar therefore appearsto be the same as a one piece Nerf bar with comparable strength andrigidity but at a lower cost as a result of savings in shipping costs.

[0024] The present invention has been described in terms of selectedspecific embodiments of the apparatus and method incorporating detailsto facilitate the understanding of the principles of construction andoperation of the invention. Such reference herein to a specificembodiment and details thereof is not intended to limit the scope of theclaims appended hereto. It will be apparent to those skilled in the artthat modifications may be made in the embodiments chosen forillustration without departing from the spirit and scope of theinvention.

What is claimed is:
 1. In an automotive Nerf bar constructed of rigidtubular material and adapted to be secured to an automotive vehicle, theimprovement comprising: (a) a plurality of abutting adjacent sections;(b) each section having a joint end for positioning opposite a joint endof an adjacent section, each joint end having an alignment notchtherein, said joint ends forming a joint between adjacent sections; and(c) a joint sleeve having an alignment pin, said sleeve extending overthe joint between said adjacent sections with said alignment pinpositioned in the alignment notches of the respective sections.
 2. Thecombination set forth in claim 1 including a support rail removablyattached to said sections and extending across said joint.
 3. Thecombination set forth in claim 1 wherein at least two of said sectionseach include mounting brackets secured to one end thereof, respectively,for attachment to a vehicle.
 4. The combination set forth in claim 1wherein at least one of said sections includes a step portion having aflattened surface for conveniently receiving the foot of a mounting ordismounting passenger.
 5. The combination set forth in claim 2 whereinsaid support rail incorporates a V-shaped cross-section with the legs ofthe “V” contacting interior surfaces of said sections on either side ofsaid joint.
 6. In an automotive Nerf bar constructed of rigid tubularmaterial and adapted to be secured to an automotive vehicle, theimprovement comprising: (a) a plurality of abutting adjacent sections;(b) each section having a joint end for positioning opposite a joint endof an adjacent section, said joint ends forming a joint between adjacentsections; (c) a support rail positioned within said sections andextending across said joint; and (d) said support rail fastened to eachsection adjacent said joint.
 7. The combination set forth in claim 6wherein at least two of said sections each include mounting bracketssecured to one end thereof respectively, for attachment to a vehicle. 8.The combination set forth in claim 6 wherein at least one of saidsections includes a step portion having a flattened surface forconveniently receiving the foot of a mounting or dismounting passenger.9. The combination set forth in claim 6 wherein said support railincorporates a V-shaped cross-section with the legs of the “V”contacting interior surfaces of said sections on either side of saidjoint.
 10. In an automotive Nerf bar constructed of rigid tubularmaterial and adapted to be secured to an automotive vehicle, theimprovement comprising: (a) a plurality of abutting adjacent sections;(b) each section having a joint end for positioning opposite a joint endof an adjacent section, each joint end having an alignment notchtherein, said joint ends forming a joint between adjacent sections; (c)a joint sleeve having an alignment pin, said sleeve extending over thejoint between said adjacent sections with said alignment pin positionedin the alignment notches of the respective sections; and (d) a supportrail mounted within said Nerf bar and extending across said joint andfastened to each of said abutting adjacent sections adjacent said joint.11. The combination set forth in claim 10 wherein said support rail isformed having a V-shaped cross-section with the legs of the “V”contacting interior surfaces of said sections on either side of saidjoint.
 12. The combination set forth in claim 10 wherein said supportrail incorporates a U-shaped cross-section with the legs of the “U”contacting interior surfaces of said sections on either side of saidjoint.
 13. The combination set forth in claim 10 wherein at least two ofsaid sections each include mounting brackets secured to one end thereofrespectively for attachment to a vehicle.
 14. The combination set forthin claim 10 wherein at least one of said sections includes a stepportion having a flattened surface for conveniently receiving the footof a mounting or dismounting passenger.